JP2019151521A - Calcium silicate plate and method for producing the same - Google Patents
Calcium silicate plate and method for producing the same Download PDFInfo
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Abstract
Description
本発明はけい酸カルシウム板およびその製造方法に関する。 The present invention relates to a calcium silicate plate and a method for producing the same.
従来、石灰質原料、けい酸質原料、パルプ等に水を加えて混合してスラリーとし、抄造機にて抄造して薄膜にし、薄膜を所定の厚みに積層する方法(以下、抄造法という。)や、型枠にスラリーを流し込み、脱水しながらプレスする方法(以下、モールド・プレス法という。)により板状に成形した後、オートクレーブで加温加圧し、養生して硬化させることでけい酸カルシウム板を得る技術があった。 Conventionally, a method in which water is added to a calcareous raw material, a siliceous raw material, pulp, etc., mixed to form a slurry, made into a thin film by a paper making machine, and the thin film is laminated to a predetermined thickness (hereinafter referred to as a paper making method). Calcium silicate by pouring slurry into a mold and pressing it while dehydrating (hereinafter referred to as mold pressing method), forming into a plate shape, heating and pressing in an autoclave, curing and hardening There was a technique to obtain a board.
しかしながら、内装下地材及び化粧パネル用の基材として使用されているけい酸カルシウム板はかさ比重が0.8〜1.0であり、一般的なサイズは3尺×6〜9尺(1.7〜2.4m2)と大きく、1枚あたりの重量が重いため、施工時の負荷が高くなっている。 However, the calcium silicate board used as a base material for interior base materials and decorative panels has a bulk specific gravity of 0.8 to 1.0, and a general size is 3 to 6 to 9 (1. 7-2.4 m 2 ) and the weight per piece is heavy, so the load during construction is high.
このような問題に鑑みけい酸カルシウム板を軽量化する方法として、パーライト、シラスバルーンのように、予め加熱発泡させた粉体をスラリー中に配合することで軽量化する方法が、例えば特許文献1に開示されている。 In view of such a problem, as a method of reducing the weight of the calcium silicate plate, for example, Patent Document 1 discloses a method of reducing the weight by adding powder that has been previously heated and foamed into a slurry, such as pearlite and shirasu balloon. Is disclosed.
しかしながら、これらの発泡体は比重が軽いため、抄造法による製造では、スラリー中で発泡体の浮遊による分離が発生する等、製造中の問題があった。また、これらの発泡体のスラリー中への添加量にも限界があり、大幅な軽量化は困難であった。 However, since these foams have a low specific gravity, there are problems during production, such as separation due to floating of the foam in the slurry in the production by the papermaking method. Further, the amount of these foams added to the slurry is also limited, and it has been difficult to reduce the weight significantly.
本発明はかかる状況に鑑み検討されたもので、(a1)石灰質原料と、(a2)けい酸質原料を高温常圧の条件にて加熱反応させることで得られるかさ比重の低い(A)反応体を製造し、得られた(A)反応体を20〜70重量%、(B)(b1)石灰質原料と(b2)けい酸質原料を含む硬化成分を25〜75重量%、(C)繊維状物質を2〜15重量%を含むスラリーとして成形することで従来品より軽量のけい酸カルシウム板を得ることができる。 The present invention has been studied in view of such a situation. (A) reaction having a low bulk specific gravity obtained by heating reaction of (a1) calcareous raw material and (a2) siliceous raw material under conditions of high temperature and normal pressure. (B) (b1) 25 to 75% by weight of a curing component containing a calcareous raw material and (b2) a siliceous raw material, (C) By forming the fibrous material as a slurry containing 2 to 15% by weight, a calcium silicate plate that is lighter than the conventional product can be obtained.
本発明のけい酸カルシウム板はかさ比重が0.48〜0.60と従来品より4割程度軽量化したにも拘らず、一般に使用される大板のサイズ(3尺×6〜9尺)でも充分な取り扱いが可能である。 Although the calcium silicate plate of the present invention has a bulk specific gravity of 0.48 to 0.60, which is about 40% lighter than the conventional product, the size of a generally used large plate (3 × 6-9 ×) But enough handling is possible.
パーライト、シラス等の発泡体を用いて本願のけい酸カルシウム板と同等のかさ比重を得るためには、パーライト等の発泡体を重量比で40%以上の添加が必要であり、抄造法では前述の理由により安定的に製造することが困難であったが、本願の製造方法によりこの問題を解決できる。 In order to obtain a bulk specific gravity equivalent to that of the calcium silicate plate of the present application using a foam such as pearlite or shirasu, it is necessary to add 40% or more of the foam of pearlite or the like in the papermaking method. For this reason, it has been difficult to manufacture stably, but this problem can be solved by the manufacturing method of the present application.
本発明に関わる(A)反応体に用いる(a1)石灰質原料としては、例えば消石灰、生石灰、ポルトランドセメント等が挙げられる。また、(a2)けい酸質原料としては、珪藻土、マイクロシリカ、シリカヒューム等を使用することができる。反応は(a1)石灰質原料と(a2)けい酸質原料とを、CaO/SiO2モル比(以下、C/Sという。)が0.4〜3.0となるように配合し、この配合物に対し、質量比で5〜20倍、好ましくは7〜16倍の水を加え、混合分散し、80〜100℃の温度で、1〜6時間にわたり反応を行う。(C/Sが上記の範囲を超えると、十分な反応体が生成されない。) Examples of the (a1) calcareous material used for the (A) reactant according to the present invention include slaked lime, quicklime, Portland cement and the like. As (a2) siliceous raw material, diatomaceous earth, microsilica, silica fume and the like can be used. In the reaction, (a1) calcareous raw material and (a2) siliceous raw material are blended so that the CaO / SiO 2 molar ratio (hereinafter referred to as C / S) is 0.4 to 3.0. 5 to 20 times, preferably 7 to 16 times as much water as mass ratio is added to the product, mixed and dispersed, and reacted at a temperature of 80 to 100 ° C. for 1 to 6 hours. (If C / S exceeds the above range, sufficient reactants are not generated.)
反応体は全成分中30〜65質量%とする。下限に満たないと、十分な軽量効果が得られない。また、上限を超えると成形体を構成する硬化成分が不足し、十分な強度が得られない。反応は常圧或いは加圧下で行うことができ、加圧下で行うことによって反応を促進できることや、反応体の結晶性を向上といったメリットがある。 The reactant is 30 to 65% by mass in the total components. If the lower limit is not reached, sufficient light weight effect cannot be obtained. On the other hand, if the upper limit is exceeded, the curing component constituting the molded body is insufficient and sufficient strength cannot be obtained. The reaction can be carried out at normal pressure or under pressure, and there are merits that the reaction can be promoted by carrying out under pressure and the crystallinity of the reactant is improved.
(B)硬化成分として(b1)石灰質原料と(b2)けい酸質原料を併用する。(b1)石灰質原料、(b2)けい酸質原料は前述と同様の原料の他、珪石微粉末、フライアッシュなどを用いることができる。(B)(b1)石灰質原料と(b2)けい酸質原料を含む硬化成分は25〜60質量%とする。下限に満たないと、成形体を構成する硬化成分が不足し、十分な強度が得られない。また、上限を超えると十分な軽量効果が得られない。(b1)石灰質原料と(b2)けい酸質原料との併用割合はC/Sで0.4〜2.0するのが好ましい。この範囲内であれば成形体の硬化が充分で強度が優れる。 (B) As a curing component, (b1) a calcareous material and (b2) a siliceous material are used in combination. As the (b1) calcareous raw material and (b2) siliceous raw material, quartzite fine powder, fly ash and the like can be used in addition to the same raw materials as described above. (B) The hardening component containing (b1) calcareous raw material and (b2) siliceous raw material shall be 25-60 mass%. If the lower limit is not reached, the curing component constituting the molded body is insufficient, and sufficient strength cannot be obtained. Further, if the upper limit is exceeded, a sufficient light weight effect cannot be obtained. The combined ratio of (b1) calcareous material and (b2) siliceous material is preferably 0.4 to 2.0 in terms of C / S. Within this range, the molded body is sufficiently cured and has excellent strength.
粉体捕捉成分として(C)繊維状物質としては、例えばパルプ、ポリプロピレン、レーヨン等の有機繊維、炭素繊維、ガラス繊維等の無機繊維を使用することができる。繊維原料の配合割合は、2〜15重量%の範囲が好ましい。下限に満たないと、抄造において、粉体原料の捕捉性が欠如し排水中への流出が多くなり安定的な製造ができなくなり、また成形体の強度も不十分になる。上限を超えると、他の原料および水と混合してスラリーを得るときに、繊維原料の分散性が低下する。 As the powder-carrying component (C), as the fibrous substance, for example, organic fibers such as pulp, polypropylene and rayon, and inorganic fibers such as carbon fibers and glass fibers can be used. The blending ratio of the fiber raw material is preferably in the range of 2 to 15% by weight. If the lower limit is not reached, in the papermaking process, the powder raw material cannot be captured, the amount of the raw material flowing out into the wastewater increases, and stable production cannot be achieved, and the strength of the molded article becomes insufficient. When the upper limit is exceeded, the dispersibility of the fiber raw material is lowered when the slurry is obtained by mixing with other raw materials and water.
前記(A)、(B)、(C)に加えて、(D)その他の成分として、30質量%以内の範囲で、ワラストナイト、マイカ、石膏、バーミキュライト、炭酸カルシウム、タルク、セピオライトなどの無機鉱物、けい酸カルシウム板の粉砕物からなる群から選択される少なくとも1種を含んでも良い。ワラストナイト、マイカを添加することで成形体の耐熱性が向上し、加熱による膨張、収縮を抑制することができる。上限を超えると、反応体の添加割合が低下することで軽量効果が不足することや、硬化成分の添加割合が低下することで成形体の強度が不足するため、好ましくない。 In addition to (A), (B), (C), (D) Other components, such as wollastonite, mica, gypsum, vermiculite, calcium carbonate, talc, sepiolite, etc. within a range of 30% by mass or less. You may include at least 1 sort (s) selected from the group which consists of a ground material of an inorganic mineral and a calcium silicate board. By adding wollastonite and mica, the heat resistance of the molded body is improved, and expansion and contraction due to heating can be suppressed. Exceeding the upper limit is not preferable because the addition ratio of the reactant is reduced, resulting in insufficient light weight effect, and the addition ratio of the curing component is reduced, resulting in insufficient strength of the molded body.
成形方法としては、押出成形法、モールド・プレス法、抄造法などの方法が採用可能であるが、抄造法を採用することで安定して製造できる。
抄造方式では、(A)反応体を30〜65重量%、硬化成分を25〜60重量%、(C)繊維状物2〜15重量%を含むスラリーを抄造・積層し、オートクレーブ加圧養生し、硬化させる。オートクレーブ養生は、例えば0.5〜1.6MPa、150〜200℃で、3〜10時間行えばよい。
As a molding method, methods such as an extrusion molding method, a mold / press method, and a papermaking method can be adopted, but stable production can be achieved by employing the papermaking method.
In the paper making method, (A) 30 to 65% by weight of the reactant, 25 to 60% by weight of the curing component, and (C) a slurry containing 2 to 15% by weight of the fibrous material is made and laminated, and then autoclaved under pressure. , Cure. The autoclave curing may be performed, for example, at 0.5 to 1.6 MPa and 150 to 200 ° C. for 3 to 10 hours.
上記の方法で得られたけい酸カルシウム板は、水銀圧入法による構造分析で、0.1μm以下の細孔容積の割合が、全細孔容積の内約70%以上であったことから、緻密かつ多孔質の構造であることが判明し、これにより、軽量化とハンドリング性の向上、及び靭性の向上ができたと考えられる。また、0.1μm以下の細孔容積が大きいことにより、環境によって水蒸気を吸放出する調湿機能を有している。尚、水銀圧入法とは、粉体の細孔に水銀を浸入させるために圧力を加え、圧力と圧入された水銀量から比表面積や細孔分布を求める方法をいう。
以下、実施例、比較例を挙げて詳細に説明する。
The calcium silicate plate obtained by the above method has a fine pore volume ratio of about 70% or more of the total pore volume in the structure analysis by mercury porosimetry. It was also found to be a porous structure, and it is believed that this enabled weight reduction, improved handling properties, and improved toughness. Moreover, since the pore volume of 0.1 μm or less is large, it has a humidity control function for absorbing and releasing water vapor depending on the environment. The mercury intrusion method refers to a method in which a pressure is applied in order to allow mercury to enter the fine pores of the powder, and the specific surface area and pore distribution are obtained from the pressure and the amount of mercury inserted.
Hereinafter, examples and comparative examples will be described in detail.
反応体(A1)
(a1)石灰質原料として消石灰(CaO含有量75質量%)を50質量%、(a2)けい酸質原料として珪藻土(SiO2含量量80質量%)を50質量%(C/S=1.1)となるように配合して、この配合物に対し、質量比で5倍の水を加え、混合分散し、常圧下、90℃の温度で、2時間にわたり加熱反応させ反応体(A1)(固形分含有量20質量%)を得た。
Reactant (A1)
(A1) 50% by mass of slaked lime (CaO content 75% by mass) as a calcareous material, and (a2) 50% by mass of diatomaceous earth (SiO 2 content 80% by mass) as a siliceous material (C / S = 1.1) ), And 5 times by weight of water is added to the mixture, mixed and dispersed, and subjected to a heat reaction at 90 ° C. under normal pressure for 2 hours to produce a reactant (A1) ( Solid content 20% by mass) was obtained.
スラリー
前記反応体(A1)65質量%(固形分値)と、(B)(b1)石灰質原料として消石灰を13質量%と(b2)けい酸質原料としてけい砂を13質量%を含む硬化成分と、(C)繊維状物質としてパルプを9質量%を配合し、9倍量の水を加えて混合分散してスラリーを得た。
Slurry component (A1) 65% by mass (solid content value), (B) (b1) 13% by mass of slaked lime as a calcareous raw material, and (b2) a hardening component containing 13% by mass of silicic sand as a siliceous raw material Then, (C) 9% by mass of pulp as a fibrous material was blended, and 9 times the amount of water was added and mixed and dispersed to obtain a slurry.
けい酸カルシウム板の製造
前記のスラリーを抄造法により厚みが6mmとなるように抄造した後、オートクレーブ中180℃の飽和蒸気圧で、10時間にわたり養生し、硬化後にオートクレーブより取り出しけい酸カルシウム板を得た。
Manufacture of calcium silicate plate After the above slurry was made to a thickness of 6 mm by a paper making method, it was cured in an autoclave at a saturated vapor pressure of 180 ° C. for 10 hours, and after curing, the calcium silicate plate was taken out from the autoclave. Obtained.
実施例1において、前記反応体(A1)50質量%(固形分値)と、(B)(b1)石灰質原料として消石灰を21質量%と(b2)けい酸質原料としてけい砂を22質量%を含む硬化成分と、(C)繊維状物質としてパルプを7質量%を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した。 In Example 1, 50 mass% (solid content value) of the reactant (A1), (B) (b1) 21 mass% of slaked lime as a calcareous raw material, and (b2) 22 mass% of siliceous sand as a siliceous raw material. This was carried out in the same manner as in Example 1 except that 7% by mass of pulp as a fibrous material (C) and a slurry in which 9 times the amount of water was added and mixed and dispersed were used.
反応体(A2)
実施例1において、(a1)石灰質原料として消石灰(CaO含有量75質量%)を36質量%、(a2)けい酸質原料として珪藻土(SiO2含量量80質量%)を64質量%(C/S=0.6)となるように配合した以外は実施例1と同様に実施し、反応体(A2)を得た。
けい酸カルシウム板の製造
前記反応体(A2)50質量%(固形分値)と、(B)(b1)石灰質原料として消石灰を18質量%と(b2)けい酸質原料としてけい砂を25質量%を含む硬化成分と、(C)繊維状物質としてパルプを7質量%を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した。
Reactant (A2)
In Example 1, (a1) 36% by mass of slaked lime (CaO content 75% by mass) as a calcareous material, and (a2) 64% by mass of diatomaceous earth (SiO2 content 80% by mass) as a siliceous material (C / S) = 0.6) The same procedure as in Example 1 was carried out except that the reactant (A2) was obtained.
Production of calcium silicate plate 50 mass% (solid content value) of the reactant (A2), (B) (b1) 18 mass% of slaked lime as a calcareous material, and (b2) 25 mass of siliceous sand as a silicate material. %, And (C) 7% by mass of pulp as a fibrous material, and a slurry prepared by adding 9 times the amount of water and mixing and dispersing was used.
実施例1において、前記反応体(A2)45質量%(固形分値)と、(B)(b1)石灰質原料として消石灰を20質量%と(b2)けい酸質原料としてけい砂を28質量%を含む硬化成分と、(C)繊維状物質としてパルプを7質量%を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した。 In Example 1, the reactant (A2) 45% by mass (solid content value), (B) (b1) 20% by mass of slaked lime as a calcareous material, and (b2) 28% by mass of siliceous sand as a siliceous material. This was carried out in the same manner as in Example 1 except that 7% by mass of pulp as a fibrous material (C) and a slurry in which 9 times the amount of water was added and mixed and dispersed were used.
実施例1において、前記反応体(A1)35質量%(固形分値)と、(B)(b1)石灰質原料として消石灰を23質量%と(b2)けい酸質原料としてけい砂を35質量%を含む硬化成分と、(C)繊維状物質としてパルプを7質量%を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した。 In Example 1, the reactant (A1) 35% by mass (solid content value), (B) (b1) 23% by mass of slaked lime as a calcareous material, and (b2) 35% by mass of siliceous sand as a siliceous material. This was carried out in the same manner as in Example 1 except that 7% by mass of pulp as a fibrous material (C) and a slurry in which 9 times the amount of water was added and mixed and dispersed were used.
実施例1において、前記反応体(A2)35質量%(固形分値)と、(B)(b1)石灰質原料として消石灰を23質量%と(b2)けい酸質原料としてけい砂を35質量%を含む硬化成分と、(C)繊維状物質としてパルプを7質量%を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した。 In Example 1, 35 mass% (solid content value) of the reactant (A2), (B) (b1) 23 mass% of slaked lime as a calcareous raw material, and (b2) 35 mass% of siliceous sand as a siliceous raw material This was carried out in the same manner as in Example 1 except that 7% by mass of pulp as a fibrous material (C) and a slurry in which 9 times the amount of water was added and mixed and dispersed were used.
比較例1
消石灰22質量%、けい砂11質量%、珪藻土11質量部、パルプ6質量%、粘土鉱物17質量%、ワラストナイト、石膏等の充填材33質量部を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した。
Comparative Example 1
Mix 22 parts by mass of slaked lime, 11% by mass of silica sand, 11 parts by mass of diatomaceous earth, 6% by mass of pulp, 17% by mass of clay minerals, 33 parts by mass of filler such as wollastonite and gypsum, and add 9 times the amount of water. This was carried out in the same manner as in Example 1 except that the mixed and dispersed slurry was used.
比較例2
消石灰24質量%、けい砂14質量%、珪藻土8質量部、パルプ6質量%、粘土鉱物17質量%、ワラストナイト、石膏等の充填材48質量部を配合し、9倍量の水を加えて混合分散したスラリーを用いた以外は実施例1と同様に実施した
Comparative Example 2
24 mass% of slaked lime, 14 mass% of silica sand, 8 mass parts of diatomaceous earth, 6 mass% of pulp, 17 mass% of clay mineral, 48 mass parts of filler such as wollastonite, gypsum, etc. are added, and 9 times the amount of water is added. This was carried out in the same manner as in Example 1 except that the mixed and dispersed slurry was used.
評価結果を表1に示す。
評価方法を以下に示す。
(1)抄造性:抄造法で成形可能な配合を○、成形不可の場合を×とした。
(2)成型体かさ比重:JIS A 5430:2013「繊維強化セメント板」に基づいて測定した。
(3)細孔構造:水銀圧入法より分析した。測定装置はMicromeritics製AutoPoreIV9520を用いて細孔径分布を算出させ、0.1μm以下の細孔比率を計算して求めた。
(4)調湿性:JIS A 1470−1:2014「建築材料の吸放湿性試験方法−第1部」:湿度応答法に基づいて測定し、吸湿量29g/m2以上を○、吸湿量29g/m2未満を×とした。
(5)ハンドリング性:軽量で取り扱いに支障のないレベルを◎、やや重いが取り扱いに支障のないレベルを○とした。
The evaluation method is shown below.
(1) Papermaking property: The compounding that can be formed by the papermaking method is indicated by ◯, and the case where it cannot be formed is indicated by ×.
(2) Molded body bulk specific gravity: Measured based on JIS A 5430: 2013 “Fiber Reinforced Cement Board”.
(3) Pore structure: analyzed by mercury porosimetry. The measuring apparatus calculated | required pore diameter distribution using AutoPoreIV9520 by Micromeritics, and calculated | required and calculated the pore ratio of 0.1 micrometer or less.
(4) Humidity control: JIS A 1470-1: 2014 “Hygroscopic absorbency test for building materials-Part 1”: Measured based on humidity response method, ○, moisture absorption 29g / m2 or more, moisture absorption 29g / less than m 2 was ×.
(5) Handling property: A light level that does not hinder handling is indicated by ◎, and a level that is slightly heavy but does not hinder handling is indicated by ○.
Claims (8)
(B)(b1)石灰質原料と(b2)けい酸質原料を含む硬化成分を25〜75重量%、
(C)繊維状物質を2〜15重量%を含むスラリーを成形して成ることを特徴とするけい酸カルシウム板。 (A) (a1) 20 to 70% by weight of a reactant obtained by subjecting a calcareous raw material and (a2) a siliceous raw material to a heating reaction,
(B) 25 to 75% by weight of a curing component containing (b1) calcareous raw material and (b2) siliceous raw material,
(C) A calcium silicate plate formed by molding a slurry containing 2 to 15% by weight of a fibrous material.
(B)(b1)石灰質原料と(b2)けい酸質原料を含む硬化成分を25〜75重量%、
(C)繊維状物質を2〜15重量%を含むスラリーを板状に成形し、硬化養生することを特徴とするけい酸カルシウム板の製造方法。 (A) (a1) 20 to 70% by weight of a reactant obtained by heating and reacting a calcareous material and (a2) a siliceous material,
(B) 25 to 75% by weight of a curing component containing (b1) calcareous raw material and (b2) siliceous raw material,
(C) A method for producing a calcium silicate plate, characterized in that a slurry containing 2 to 15% by weight of a fibrous material is formed into a plate shape and cured and cured.
6. The method for producing a calcium silicate plate according to claim 5, wherein the forming is performed by a papermaking method.
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JPH08325074A (en) * | 1995-05-30 | 1996-12-10 | Ask:Kk | Calcium silicate plate and its production |
WO1999042418A1 (en) * | 1998-02-23 | 1999-08-26 | Asahi Kasei Kogyo Kabushiki Kaisha | Cured calcium silicate object with high strength |
JP2001518867A (en) * | 1997-04-10 | 2001-10-16 | ジェイムズ ハーディ リサーチ プロプライアトリー リミテッド | Building products |
JP2007131488A (en) * | 2005-11-10 | 2007-05-31 | Tokyo Institute Of Technology | Calcium silicate hydrate solidification product and its synthesis method |
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JPH08325074A (en) * | 1995-05-30 | 1996-12-10 | Ask:Kk | Calcium silicate plate and its production |
JP2001518867A (en) * | 1997-04-10 | 2001-10-16 | ジェイムズ ハーディ リサーチ プロプライアトリー リミテッド | Building products |
WO1999042418A1 (en) * | 1998-02-23 | 1999-08-26 | Asahi Kasei Kogyo Kabushiki Kaisha | Cured calcium silicate object with high strength |
JP2007131488A (en) * | 2005-11-10 | 2007-05-31 | Tokyo Institute Of Technology | Calcium silicate hydrate solidification product and its synthesis method |
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WO2021033771A1 (en) | 2019-08-21 | 2021-02-25 | 株式会社タダノ | Work machine |
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